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| United States Patent |
5,512,310
|
|
Graef
|
April 30, 1996
|
Process for the wetting of cereals with a liquid
Abstract
A process for the wetting of cereals with a liquid, wherein the
cereal/liquid mixture is exposed for a short time (2 to 15 seconds) to
strong vibration (shaking at approximately 80 Hz), with the result that
the cereals directly absorb the liquid into themselves and immediately
become transportable and can be further processed, for example can be
ground, without a substantial storage time. (FIG. 1).
| Inventors:
|
Graef; Dieter O. (Neumuehle, D-35633, Lahnau-Dorlar, DE)
|
| Appl. No.:
|
193010 |
| Filed:
|
February 17, 1994 |
| PCT Filed:
|
August 12, 1992
|
| PCT NO:
|
PCT/EP92/01843
|
| 371 Date:
|
February 17, 1994
|
| 102(e) Date:
|
February 17, 1994
|
| PCT PUB.NO.:
|
WO93/03843 |
| PCT PUB. Date:
|
March 4, 1993 |
Foreign Application Priority Data
| Aug 17, 1991[DE] | 41 27 290.0 |
| Current U.S. Class: |
426/507; 99/536; 426/519 |
| Intern'l Class: |
A23L 001/00 |
| Field of Search: |
426/237,238,507,519,618
99/516,536,471
366/114,115,178
|
References Cited
U.S. Patent Documents
| 4055673 | Oct., 1977 | Mueller et al. | 426/519.
|
| Foreign Patent Documents |
| 796098 | Mar., 1936 | FR.
| |
| 2234040 | Jan., 1975 | FR.
| |
| 2540746 | Aug., 1984 | FR.
| |
| 6577 | Jul., 1892 | DE.
| |
| 87456 | Jul., 1896 | DE.
| |
| 664616 | Sep., 1938 | DE.
| |
| 2331842 | Jan., 1975 | DE.
| |
| 2406874 | Aug., 1975 | DE.
| |
| 9112458 | Dec., 1991 | DE.
| |
| 234921 | Mar., 1945 | CH.
| |
| 1094591 | Dec., 1967 | GB.
| |
| 1462904 | Jan., 1977 | GB.
| |
Other References
Database WPIL, section CH, week 8842, Derwent Publications Ltd., AN
88-298446 6 SU, A, 1 386 290 Apr. 7, 1988, abstract.
|
Primary Examiner: Yeung; George
Attorney, Agent or Firm: Foley & Lardner
Claims
I claim:
1. Process for the wetting of cereals with a liquid, comprising the steps
of:
mixing the cereals with a liquid, wherein at least a portion of the cereals
have husks;
and subsequently exposing the mixture to vibrations in a shaking apparatus
sufficient to impart acceleration forces to at least a portion of said
cereal/liquid mixture by the contact of at least a portion of the
cereal/liquid mixture with a vibrating wall of said apparatus, which
acceleration forces provide a substantially uniform wetting of said
cereals and a substantially uniform penetration of the liquid from the
husk into the inside of the cereal.
2. Process according to claim 1, wherein the cereals are exposed to the
vibrations during the addition of the liquid.
3. Process according to claim 1, wherein the cereals and the liquid are
vibrated by vigorous shaking.
4. Process according to claim 3, wherein the cereal/liquid mixture is
shaken in at least one pipe of said shaking apparatus, in such a way that
the at least one pipe transmits its kinetic energy to the cereal/liquid
mixture.
5. Process according to claim 3, wherein the cereal/liquid mixture is
shaken at a frequency of 50 to 300 Hz.
6. Process according to claim 3, wherein the shaking time is approximately
2 to 20 seconds.
7. Process according to claim 3, wherein the shaking takes place by means
of at least one of mechanical energy, electrical energy, magnetic energy
and by exposure to sonic waves.
8. Process according to claim 3, further comprising the steps of
introducing the cereals mixed with liquid continuously and/or
discontinuously into a shaking apparatus, running the mixture through the
apparatus, with at least partial shaking, wherein the mixture emerges or
is extracted from the shaking apparatus by at least one of continuously
and discontinuously.
9. Process according to claim 4, wherein the cereals are arranged compactly
in the at least one pipe or run through the at least one pipe.
10. Process according to claim 3, wherein the shaking is preceded by mixing
in a mixing apparatus.
11. Process according to claim 3, further comprising the steps of feeding
the cereals to a funnel in such a quantity that they stream out of the
lower funnel orifice and fall over the upper edge of the funnel, and
directing liquid into the filling orifice of the funnel, wherein the
cereals thus moistened are directed or fall into the shaking apparatus.
12. Process according to claim 3, wherein the cereal/liquid mixture is
shaken at approximately 10 to 15 g (g=acceleration due to gravity).
13. Process according to claim 1, wherein the cereals are at least one of
crops with a hard and soft husk, husked rice, beans and crops which can be
extruded.
14. Process according to claim 1, wherein the liquid is at least one of
water, sugared water and molasses.
15. Process according to claim 1, further comprising the step of adding to
the liquid at least one additive soluble therein which varies at least one
property of the cereals.
16. Process according to claim 3, wherein the cereals mixed with the liquid
are shaken several times at selected time intervals.
17. Process according to claim 16, wherein the time interval is
approximately 30 minutes to 5 hours.
18. Process according to claim 16, wherein the cereals are used in brewing
for the production of malts, and are shaken at time intervals, with liquid
being added at each time interval.
19. Process according to claim 3, wherein the cereals are shaken without
damage to their surface.
20. Process according to claim 1, wherein the cereals are exposed to
vibrations in such a way that an osmotic pressure effect is exerted on
them when they run through the apparatus.
21. Process according to claim 1, wherein the cereals are grindable corn
grains.
22. Process according to claim 1, wherein the cereals are subsequently used
in an extrusion process after said vibrating step.
23. Process according to claim 5, wherein said frequency is about 75 Hz.
24. Process according to claim 1, wherein said strong acceleration forces
are about at least about 5 g.
25. Process according to claim 16, wherein the selected time intervals are
at least one of increasing and decreasing.
26. Process according to claim 15, wherein the at least one property varied
is crude fiber, starch, proteins, fats and mucous substances.
Description
DESCRIPTION
The invention relates to a process for the wetting of cereals, especially
corn grains, with a liquid, designated hereafter for the sake of
simplicity as water, and to an apparatus for carrying out the process.
To obtain flour, for example, the flour body (endosperm) of a corn grain is
separated from the husk (bran and germs). For this purpose, the corn
grains are wetted with water, so that their husk can be softened and
subsequently separated more effectively during the grinding operation.
According to the state of the art such as disclosed in FR-A 2,540,746, the
corn grains are moved about and, at the same time, mixed with water in a
conveying worm. Thereafter, the cereal/liquid mixture is allowed to rest
for 10 to 24 hours, depending on the grain quality, so that the water can
soften the husk and penetrate inside the kernel. These long standing times
are a great disadvantage, since a large space capacity is required for
storage during the standing time. This necessary space capacity often
restricts the maximum production capacity of a mill.
Furthermore, the long standing time has an adverse effect on the flour
quality, since, on account of the dampness of the grain, molds and yeasts
and/or bacteria (for example, enterobacterium C) often form and multiply
during the long storage time. For this reason, the netted worm, which has
a length of between 3 and 8 meters and which is a good seat of germs for
mold and/or bacteria, so that the worms must be cleaned frequently, thus
leading to interruptions and greatly disrupting the continuous flow.
Similar problems occur in the treatment of other cereals, in which the husk
is to be separated from the kernel, such as pulses, maize, rice, beans,
also coffee beans, cocoa beans and the like. In brewing too, during the
production of a malt, the problem of the long standing time of 80 to 100
hours and more occurs particularly, since the wetted grains are to absorb
an especially high water content so that they begin to germinate. FR-A
2,234,040 discloses mixing cereal and water for the malting process by
means of nozzles arranged along a conveying table which moves the cereal
forward by vibration. This arrangement provides for good mixing, but does
not cause the water to penetrate quickly into the husk, thus necessitating
a long standing time.
Consequently, the term "cereals" is to embrace all crops which have a
kernel and a hard or soft husk or skin surrounding the kernel.
Water can serve as a liquid for treatment. If, for example, maize is to be
processed as an extruder product to form popcorn, sugar will be added to
the liquid (water) that is to say sugared water will be used. Molasses can
come under consideration as a liquid for the preparation of cattle feed.
The object of the invention is to indicate a wetting process for cereals,
in which the cereals are wetted with liquid in such a way that the
standing time as storage time virtually disappears, and in which the
transportability of the cereals wetted with liquid is provided directly,
that is to say immediately or after only 10 to 30 minutes.
By transportability it is meant that the cereals wetted, for example, with
water no longer have any outer water film which results in adhesive
bonding to the means of transport (bands, worms or the like).
This object is achieved by means of an apparatus and process that mixes
cereal with liquid and subsequently subjects the mixture to vibration.
It has been shown that, when the cereals mixed with water are exposed to
vibrations, that is to say are shaken vigorously, for example at a
frequency of 50 to 300 Hz, preferably 75 Hz, over a period of 2 to 20
seconds, the acceleration forces exerted on the cereal/liquid mixture by
the wall of the shaking apparatus cause all the water already to penetrate
so far into the cereals, at least in their husks, that, although the husks
are still felt to be moist on the outside, nevertheless a water film on
the cereals can no longer be felt and also is no longer present.
This shaking operation can take place in a careful way, that is to say in
such a way that the husks of the cereals are not damaged, so that the
liquid directly penetrates in a uniformly distributed manner via the husk
of each grain into the latter.
It has been shown, furthermore, that, when the process according to the
invention is used, the grindability of such a grain is provided after only
30 minutes to 2 hours, depending on the addition of water, because, in
particular, the husk then has the desired degree of moisture uniformly
distributed over the entire husk of each grain and can therefore be
separated effectively during the grinding operation. There is no need for
a long storage of the cereals in order to obtain a uniform moistening with
a desired degree of moisture, as in the state of the art.
According to the invention, therefore, the husk of the grain is first
permeated uniformly with moisture relatively quickly, and the moisture
then penetrates from the husk into the inside of the grain relatively
uniformly from all sides.
The advantage of the process according to the invention is thus to be seen
in that the grain, after wetting, can be transported to its processing
point immediately or after a short dwell time, in order, for example, to
be ground directly there, and in that there is no need for intermediate
storage of the grain.
It has been shown, moreover, that, in order to obtain a grindable grain,
the entire water quantity required can be fed at once, in a single
operation, to the cereals, especially to the corn, thereby saving
considerable time for the wetting of the corn grains. In the processes
which belong to the state of the art and which work with a conveying worm,
a plurality of additions of water at time intervals are necessary.
According to the invention, a plurality of additions of water at time
intervals are necessary only when the grain, including its kernel, is to
absorb a very large quantity of water, for example up to 40 or 50 percent
by weight, in order to set in motion the germination process for the
production of a malt in the malthouse.
Furthermore, the advantage of the process according to the invention is
that, for example, there is no longer any need for a netting worm for
mixing the corn with the water, since other simpler means are expedient,
such as a simple agitator or a funnel arrangement. Greater cleanliness and
therefore better hygiene are achieved thereby. Moreover, an energy saving
is obtained, since the drive of the netted worm or of similar apparatuses
requires considerably more energy than the shaking apparatus according to
the invention.
Above all, however, particularly bacteria and fungi have less opportunity
to multiply as a result of the absent storage time.
The apparatus according to the invention expediently consists of a pipe
which has a preferably vertically arranged axis and which is connected,
for example approximately in its middle, to a shaking motor or a plurality
of shaking motors. The cereals, mixed with liquid, for example water, can
be introduced into the pipe at the top, and they run out again at the
bottom. The throughflow quantity can be regulated by means of measuring
and control devices. The dwell time of the cereal/liquid mixture in the
pipe can thereby be regulated. In particular, there can be provided at the
lower end of the pipe a discharge element which extracts the cereals in
the desired quantity from the pipe either continuously or discontinuously.
Such a discharge element can be formed, for example, by a cone which is
introduced to a greater or lesser extent into the pipe end and which thus
either completely interrupts the outflow stream of cereals or selectively
allows specific cereal/liquid mixture quantities to escape. However,
cellular-wheel sluices, shaking troughs, slides of all kinds or conveying
worms also come under consideration for this purpose.
In principle, however, the pipe can also be arranged with a horizontal
axis, so that the cereals are pushed in from one side. This shaking can be
appropriate when the cereal/liquid mixture is to be shaken in batches.
Advantageously, the pipe has smooth walls on the inside, so that, in
particular, the husks of the cereals are not damaged during shaking,
because, as already stated if the husks are damaged, the water penetrates
into the husk non-uniformly, namely first at the damaged points, so as to
advance from here on the one hand further in the husk and on the other
hand into the kernel. As a result, the husk is moistened non-uniformly,
and therefore the desired exact separation of the husk and kernel during
the grinding operation is adversely influenced. This is because, at the
points at which the husk is not yet sufficiently moistened, kernel pieces
of the grain still adhere firmly to the husk and remain caught on the husk
during the grinding operation.
Furthermore, the pipe can have intermediate walls, so that the maximum
distance of each grain from one of the walls set in vibration remains
small. The cereal/liquid mixture thereby acquires high acceleration during
the shaking operation, namely of the order of 5 g to 15 g (g=acceleration
due to gravity). Despite this high acceleration, the cereal/liquid mixture
does not strike hard against the walls, since the grains mixed with liquid
are arranged relatively compactly in the pipe or in the pipe chambers,
that is to say the transmission of energy to the cereal/liquid mixture
does not take place as a result of hard hocks against this mixture, but
because the grains and, if appropriate, the liquid droplets bear against
the pipe wall or an intermediate wall. Under these acceleration forces,
the liquid itself breaks up into very fine droplets which settle directly
on the husks of the cereals and penetrate into the husks.
An appreciable further advantage of the process according to the invention
is seen in that, in a further embodiment of the invention, additives can
be added to the liquid. Enzymes, such as proteinases, proteases or the
like, vitamins, such as ascorbic acid, nitrates, salts and/or sugar can be
provided as additives. These additives dissolved in the liquid can vary
the properties of the cereals, such as crude fibers, starch, proteins,
fats and/or mucous substances, also the cell structures and consequently,
for example, the grindability of the grains.
This introduction of the additives into the cereals directly together with
the liquid during shaking has the following advantages, for example in
flour production:
1. The introduction of additives into the grain before the grinding
operation is cheaper than the introduction of additives after the grinding
operation by addition to the flour, in which case, according to the state
of the art, the additive, for example vitamin C, is added in powder form
to the flour.
2. The process according to the invention can be carried out more quickly
in time, since, for example in the production of flour, the husks or the
flour, after the grinding operation, no longer have to be mixed separately
with the powdery additives.
3. The addition of the additives according to the state of the art in
powder form can be harmful to health, for example if the additives are
breathed in. However, they are also frequently incompatible with the human
skin.
4. The mixing of flour with the additives according to the state of the art
necessitates a very thorough mixing of the flour with the additives. By
means of the process according to the invention, an exceedingly uniform
distribution of the additives in the flour is achieved in the simplest
way. The mixing with the additives is therefore no longer as
cost-intensive and as time-consuming as in the state of the art.
Furthermore, as already mentioned, in addition to the sectors of use stated
hitherto, the process according to the invention can be used for the
production of malts, such as are required by the beer brewer, in that the
cereals are expediently shaken several times at time intervals, along with
the addition of a liquid. As a result, more liquid, for example water, can
be bound in the cereals in a short time, that is to say the percentage
weight fraction of liquid in the grain can be increased well above the
customary amount, so that the corn grains begin to germinate in a
substantially shorter time. In this particular use, therefore, it is
important that a large quantity of water is absorbed by the endosperm
itself, in order to bring the grain to germination.
Exemplary embodiments of the invention are illustrated in the drawing, in
which:
FIG. 1 shows a first exemplary embodiment in section;
FIG. 2 shows a section along the line II--II of FIG. 1;
FIG. 3 shows a modified exemplary embodiment according to FIG. 2;
FIG. 4 shows a modified exemplary embodiment according to FIG. 2;
FIG. 5 shows a modified exemplary embodiment.
According to FIG. 1, corn grains (100) are introduced into a funnel (102)
in the direction of the arrow (101), specifically in such a way that fewer
corn grains run out of the funnel orifice (103) than are introduced at the
top, so that the corn grains spill over the upper edge (104) of the funnel
and fall past this through the lower orifice (105) of an outer funnel
(106) surrounding the funnel (102). Water is fed to the corn grains in the
region of the funnel (102) by means of an inflow (107).
However, a simple agitator or another apparatus can also serve for mixing
the cereals with the water.
The corn grains thus mixed with water fall through a widened orifice (110)
of an approximately vertically arranged pipe (111). The pipe (111) is
mounted on a fixed frame mount (113) by means of rubber buffers (112), in
such a way that it can execute movements in the direction of the arrow
(115) and its upper part (111a) and the lower part (111b) can oscillate
transversely to the axis A--A of the pipe in the direction of the arrow
(115). The pipe (111) carries a cuff (116) which is firmly connected to a
shaking motor (114). When the armature of the shaking motor (114) rotates,
the cuff (116) and therefore the middle part of the pipe moves to and fro
in the direction of the arrow (115), and the ends of the pipe oscillate in
the direction of the arrows (117 and 118). A sharp acceleration is thereby
imparted via the wall of the pipe (111) to the corn-grain/liquid mixture
introduced in the pipe (111), and this acceleration breaks up the liquid
by means of imparted vibrations into very fine droplets and distributes
then rapidly and uniformly over the entire husk and causes them to
penetrate into the husk and from here into the grain. During this
operation, the cereals mixed with the water stream from the inlet orifice
(110) to the outlet orifice (121). Here, they strike against a closing
cone (120) which can be introduced into an outlet orifice (121). Depending
on the position of the cone (120) in the outlet orifice, more or fewer
cereals can fall past the cone (120). The position of the cone (120) and
the length of the pipe consequently determine the dwell time of the
cereal/liquid mixture in the pipe (111).
However, instead of the cone, a cellular-wheel sluice known per se, a slide
mechanism, a vibrating trough or the like can also be suitably connected
to the pipe.
The grain can also run through in batches. In this case, the outlet orifice
(121) is closed and, after the introduction of the cereal/liquid mixture,
the pipe is shaken for a predetermined time. After the outlet has opened,
the wetted cereals flow out of the pipe, and the pipe can be refilled.
A control device (130) is provided for the continuous run-through of the
cereals. The control device (130) receives measured values from a
measuring sensor (131) which indicates the throughflow quantity of the
cereals into the pipe (111). The device (130) regulates the refilling of
the funnel (102) with cereals and water. A measuring device (132) measures
the outflow quantity of the cereals from the pipe (111). The measuring
device (130) controls this outflow quantity and therefore the dwell time
of the cereals in the pipe. During the shaking operation, the
cereal/liquid mixture rests compactly in the pipe, so that, during
shaking, it does not strike against the pipe wall too hard, but on the
contrary is exposed to only high acceleration forces.
2 to approximately 15 seconds or more of shaking time are usually required
for one pipe filling, that is to say the cereals which have entered at the
top are to be shaken in the pipe for approximately 2 to 15 seconds or
more, specifically irrespective of whether they are introduced into the
pipe and shaken in batches or run continuously through the pipe. The
length of the pipe is dimensioned accordingly. A pipe of a length of one
meter is normally sufficient.
The cereals emerging from the pipe (111) at the bottom fall through a guide
pipe (140) onto a distributor plate (141) and from here into a collecting
container (142). The emerging cereals are directly transportable, so that
by means of conveyor bands, worms and the like, without adhering to these
parts as a result of adhesive forces, they can be transported further to a
processing point, without any appreciable period of intermediate storage.
A pipe (111) can have a circular, elliptic or rectangular, even square
cross section. It is merely to be ensured that, during the shaking
operation, the cereals acquire their acceleration energy to a sufficient
extent from the inner wall of the pipe.
In order to make it possible to cause larger quantities to run through, the
diameter of the pipe (111) can be increased. However, the shaking effect
consequently decreases towards the inside of the pipe, since the
transmission of energy of the cereal/liquid mixture from grain to grain
becomes lower towards the middle of the pipe. Consequently, in a further
exemplary embodiment according to FIG. 3, there are provided in the
interior of a pipe (122) longitudinal walls (150) which form further
energy-transmitting walls for the cereal/liquid mixture running through.
Another solution to this problem is illustrated in FIG. 4. Three pipes
(151, 152, 153), which are firmly connected to one another and which can
be shaken jointly, are provided here.
FIG. 5 shows the pipe (123) with incorporated intermediate walls (124), so
that rectangular spaces (125) are obtained in the pipe over the length of
the pipe, the transverse walls being at a relatively small distance from
one another, so that the rectangular spaces become very narrow. When such
a pipe is shaken at a frequency of 75 to 80 Hz, the pipe walls impart to
the cereal/liquid mixture an acceleration of five to fifteen times the
acceleration due to gravity, with the result that the liquid breaks up and
wets the cereals uniformly, in such a way that the liquid penetrates
directly into the husks of the cereals. This penetration and also the
further penetration of the liquid into the kernel of the cereals is
assisted by the acceleration forces exerted on the cereals.
______________________________________
Reference numerals
______________________________________
100 Corn grains
101 Arrow
102 Funnel
103 Funnel orifice
104 Upper edge
105 Lower orifice of 106
106 Outer funnel
107 Water inflow
110 Widened orifice
111 Pipe
111a Upper part of the pipe
111b Lower part of the pipe
112 Rubber buffer
113 Frame mount
114 Motor
115 Arrow
116 Cuff
117, 118 Arrows
120 Closing cone
121 Outlet orifice
122 Pipe
123 Pipe
124 Intermediate walls
125 Elongate rectangular spaces
130 Control device
131 Measuring sensor
132 Measuring device
140 Guide pipe
141 Distributor plate
142 Collecting container
150 Intermediate walls
151, 152, 153 Pipes
A-A Pipe axis
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